1. Vacuum Regulator Gas Feed Systems: Theory and Maintenance
Thom DiGeronimo
OperatorSchool.Com
All Text, drawings and photographs Copyrighted 2005 by T DiGeronimo
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2. Seminar Highlights Gases and Properties The Vacuum Regulator / Ejector
Element theory and function
Differences by manufacturers
Work and safety practices
Personnel & Equipment Safety
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3. History of the Vacuum Regulator 1
Before 1960, when James Haskett, Chlorinators Inc. founder, designed and patented the cylinder-mounted all-vacuum-operated gas chlorinator, most chlorinators worked essentially the same way. Pressure from the tanks forced the gas through one line to an ``ejector“ where it was mixed with water. Water pressure then forced the chlorine/water solution through another line to the ``diffuser" that injected it into the water or wastewater being treated. If either line failed, gas would escape unimpeded. Failure of any of the many valves these systems employed would also cause gas to escape. Haskett's design -- mounting the chlorinator on the cylinder and using a vacuum to pull the gas to the ejector -- eliminated the gas pressure line. This design makes it very difficult for chlorine to escape. If any part of the equipment should fail, the flow of chlorine is immediately -- and automatically -- shut off. The problem of corrosion, which contributed to the difficulties of the pressure systems, is also significantly reduced by Mr. Haskett's design, and the pressure line, the most serious source of corrosion in gas chlorination equipment, is eliminated.

4. History of the Vacuum Regulator 2
In Mr. Haskett‘s design, chlorine gas bubbles immediately enter the main stream, and are quickly dissolved. Further, beginning with the regulator, the gas is never under pressure, and it is mixed with water in the ejector under vacuum conditions. Another important point: laws prohibiting the use of chlorine gas could be costing you a lot of money, because chlorine gas is far more economical than either sodium or calcium hypochlorite. The tank contains 100% chlorine, which can never lose strength. Calcium hypochlorite has only 65-70% total weight chlorine available, and sodium hypochlorite only 10% or less by the time it is used. You need 1.5 pounds of calcium hypochlorite, or 1.2 gallons of sodium hypochlorite (average 10%) to equal a pound of liquid (gas) chlorine. Both calcium and sodium hypochlorite lose strength in storage. Although the initial cost of gas chlorination equipment may be higher than that required for calcium or sodium hypochlorite, the savings in material costs quickly make up the difference.
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5. 3/25/2017

6. Chlorine Gas Properties
Amber Gas & Liquid
Expands 460 Times
Corrosive
Non Flammable
3PPM
Heavy Gas Will Flow
Chlorine Institute
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7. Sulphur Dioxide Gas Properties
Gas & Liquid
Expands many Times
Corrosive
Non Flammable
3PPM
Heavy Gas will Flow
CGA makes rules
Overfilled Tanks can explode !!!
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8. Liquid to Gas Properties
Coefficient of expansion
Needs minimum headroom
With a FULL TANK Liquid expansion at any temperature can cause the tank to fail or explode !!
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9. Safety “Equipment” Required SCBA / Face Mask Filter Gas Leak Detector Leak Repair Kit A or B Properly Trained Haz-Mat People A PLAN
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10. Safety is ALWAYS FIRST !!! OBEY YOUR SAFETY RULES
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11. Tank Valves & Fusible Plugs for 150’s
w/ Fusible plug -- Flex Connector Yoke -- Manifold Valve
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12. Valves & Accessories
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13. Approved 150 lb Cylinder Storage
Straps & Blocks - NO CHAINS - Straps & Rack
Valve Covers on When NOT Being Used
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14. Un-Approved 150 lb Cylinder Capture
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15. Ton Cylinder Fusible Plugs & Valves
3 3/4 “ Fusible Plugs on Both Ends of Cylinders
Valve Safety Cover Gas & Liquid Valves
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16. Ton Cylinder Valves Gas Valve (TOP) to the Right
Liquid Valve (BOTTOM) to the Left
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17. Ton Cylinder Eductor Tubes
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18. Safety – IT IS YOUR JOB !!
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19. Proper Materials used Properly
Body Plastics
Metals / Hardware
O rings / Gaskets
Tubing
Piping
Valves
Safety & Function
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20. Basic Vacuum Regulator Body
Two Parts Separated by a Diaphragm
Front is Vent Cavity
Back is Vacuum Regulation
Inlet Valve Mounting
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21. Vacuum Regulator Diaphragm
Flexured Plastic Material Separates Body Cavities
Front has pin for Indication and Control
Back has Vent Valve
Can be Spring Loaded to Inlet Valve
Uses Vacuum / Barometric Pressure to Open Inlet Valve
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22. Standard Hydro Regulator
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23. Inlet Valve Assembly
Grooved Body Alumina Bronze ( Better: Hastalloy C)
Guts Teflon, Monel ABS / PVC
Gaskets / O Rings Viton or Buna N
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24. Inlet Valve Detail Vent Seat Vent Plug Valve Spring Assy Inlet Seat
Inlet Plug
Inlet Filter
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25. NXT 3000 Parts Breakdown
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26. Hydro 100 PPD Latching Regulator
Vent Connection
Switchover knob
Rotameter
Gas Connection
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27. Quick Tour around the Hydro 100 PPD Regulator w/ Switchover
Vent Connection
Switchover knob
Rotameter
Gas Connection
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28. NXT-3000 Latching Regulator Arm Latch Positions
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29. NXT-3000 Latching Regulator Pivot Latch Lift Arm
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30. NXT-3000 Latching Regulator Diaphragm Lift Eye
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31. NXT-3000 Latching Regulator Diaphragm Lift Eye Pivot Plate
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32. NXT-3000 Latching Regulator Latching Lift Arm
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33. Auto-Switchover Valve
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34. Quick Tour around the Hydro 100 PPD Regulator
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35. Yoke & Inlet Valve Assembly
Mounts the Regulator
Inlet Valve Seals to Bottle
Lead Washer Gasket
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36. Hydro Ton Mount Regulator
Inlet is the same
Yoke turned to right
Drip leg added
25 W Heater added
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37. Flowmetering w/ Ecometrics @ 500 PPD
Rotameter
Metering Valve
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38. ABS / PVC Body - Viton / Buna N Gaskets & O Rings
Ejector Designs
ABS / PVC Body - Viton / Buna N Gaskets & O Rings
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39. Ejector Sizing Charts Proper Inlet & Outlet Pressures
Proper Installation / Position
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40. Ejector Application by Diffuser
Must Not Back Up Flow
Must “Diffuse” the Solution in Flowstream
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41. Typical Systems 1 -- Capital Controls
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42. Typical Systems 2 -- Capital Controls
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43. Typical Chlorine – Sulfur Dioxide Room
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44. Liquid Cl2 Damage # 1
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45. Liquid Cl2 Damage # 2 NXT3000 Back Body\ $350.00 … Look on Boss
PRICELESS !!
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46. Liquid Cl2 Damage # 3
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47. Liquid Cl2 Damage # 4
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48. Main Diaphragm “Melted” / Deformed
Liquid Cl2 Damage # 5
Main Diaphragm “Melted” / Deformed
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49. Liquid Cl2 Damage # 6 Also Caused By Wrong Lubes Water in System
Condensation
Intervals
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50. Basic Regulator / Ejector Materials
Cl2 Regulator Bodies – ABS Plastics
Cl2 & SO2 Ejector ABS & PVC Plastics
Tubing – Polyethylene & Teflon – Kynar
O-Rings & Gaskets Viton & Buna N
Inlet Block – Hastelloy Alumina-Bronze & Kynar
Inlet Valve – Silver, Hastelloy & Stainless Steel
Screws – Monel or Titanium
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51. Cleaning Materials Dish Soap & Water Alcohol on MOST Plastics
Lacquer Thinner on Teflon & Metals Soaking
Lacquer Thinner “Flash” Wipe on Plastics *** Caution – This WILL Melt Plastics ***
Vinegar or Muriatic Acid for Corrosion Removal
3-M Pads for Plastic Abrasion
“00 – Fine” Steel Wool for Metal Abrasion
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52. Maintain Equipment Properly # 1 Lubes
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53. Maintain Equipment Properly # 2 Lubes
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54. Maintain Equipment Properly # 3 Lubes
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55. Maintain Equipment Properly # 4 Lubes
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56. Maintain Equipment Properly # 5
Routinely
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57. Liquid Traps
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58. Liquid Trap Avoidance # 2
Custom
Made
Flex
Connector
30 Inches
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59. Modified Drip Leg Liquid Trap
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60. Service Systems 1 www.OperatorSchool.com www.Start-UpService.com
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61. Service Systems 2 www.OperatorSchool.com www.Start-UpService.com
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62. Where to Get More Information
Chlorine Institute
A.W.W.A. Manuals
Manufacturers Manuals
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